New Automation Technology

PC-based control for Wind Turbines

Facts and figures

Headquarters: Verl, Germany

Employees worldwide: 3,900

Number of engineers: 1,400

Sales/technical offices in Germany: 22

Beckhoff companies worldwide: 37 countries

Subsidiaries and distributors: 75 countries

Sales worldwide 2016 679 million € (+9.5 %)

Sales worldwide 2017 810 million € (+19 %)

as of: 04/2018

Verl

Components for Industrial Automation

The IPC Company The Automation Company

The I/O Company The Motion Company

Germany

Headquarters

Office

Development Center

Sales Office

New Offices 2017

New Offices 2018

Technical Office

Production

Lübeck

Münster

Verl

Frankfurt

Nuremberg

HanoverBerlin

Moers

Marktheidenfeld

MunichBalingen

Regensburg

Deggendorf

Ravensburg

CrailsheimPforzheim

Schortens

Halle

DresdenMonheim

Hamburg

Mannheim

Fulda

Erfurt

Freiburg

Production in Verl

Worldwide

Saint Petersburg

VerlMississaugaMinneapolis

San Luis Potosí

Moscow

Ekaterinburg

Istanbul

Peking

Shanghai

SeoulYokohama

Beirut

Chengdu

Lod

Taipei

Guangzhou

Bangkok

AucklandMelbourne

Kuala Lumpur

Jakarta

Johannesburg

São Paulo

Montevideo

Bogotá

Santiago

Pune

Dubai

Silicon Valley

Lima

Quito

Cairo

Taichung

Mexico City

Beckhoff subsidiary

New Beckhoff subsidiary/office/distributor (2017)

New Beckhoff subsidiary in preparation (2018)

Beckhoff distributor

Buenos Aires

Haarlem

Singapure

Food IndustryEnd User

Applications and solutions

Wire | Cable | Pipe

Semiconductor

Manufacturing

Medical Engineering Energy Industry

Transport | Logistics Textile Industry Machine Building

Applications and solutions

Building Automation Process Industry Test Facilities

Water Treatment Photovoltaic Automotive

Shipbuilding Stage Technology Wind Turbines

Condition Monitoring | Current Situation

Drive Train

Monitoring

Tower

Monitoring

Blade

Monitoring

Blade Bearing

Monitoring

Power

Monitoring

Environment

Monitoring

Condition Monitoring | Current Situation

Black Boxes for each Monitoring Task

Interface work for each device

Each device contains own CPU and infrastructure components

Each device needs additional Data like power, speed, windspeed etc.

Measured values are not time synchronized

Different data formats

Data concentration (loss of data) in many devices

Many different hardware suppliers

High cost level

Interface to the WTC

Slipring

Blade Monitoring

Tower MonitoringDrive Train Monitoring

Blade Bearing Monitoring

Condition Monitoring | Beckhoff Approach

1 Hardware, 1 Database, 1 Timebase, 1 Infrastructure

Electrical Power Monitoring

Drive Train Monitoring

Blade Monitoring

Blade MonitoringDrive Train Monitoring

Condition Monitoring | The Beckhoff Approach

1 Hardware, 1 Database, 1 Timebase, 1 Infrastructure

One Hardware, one interface, one solution for all tasks

Collection of all raw data

All measured values are time synchronized << 1 µs

All data could be stored in one data base

Terminals for all relevant sensors are available

Interfaces to the WTC are all available

Power, speed, windspeed etc. are available for all tasks

3rd party software suppliers offer software for all monitoring tasks on a turbine

Licensing for 3rd party software based on TwinCAT3 licensing

Ability to integrate own measurement campaigns into the system

Safety input

Safety input Safety output

Hub Nacelle

Tower

Wind Farm

Condition

Monitoring

Ethernet TCP/IP

Ethernet TCP/IP

CANopen

PROFIBUS

Ethernet TCP/IP

PROFIBUS

CANopenDVI/USB

Safety logic

EtherCAT (fibre-optic cable)

Condition Monitoring

Integrated

Control Panel

Ethernet TCP/IP

Converter

Power

Monitoring

Big Data

ADS

OPC-UA

IEC 61400-25

IEC 61850

IEC 60870-5-104

Modbus TCP

Measurement technology

1-channel measurement

terminal, parameterisable

voltage measurement

current measurement

resistance measurement

electrical resistance R in 2-

/3-/4-wire connection

RTD measurement in 2-/

3-/4-wire connection

strain gauge/load cell

¼-bridge, ½-bridge or full

bridge

potentiometer

EtherCAT Terminals

EL3751 | Analog multi-functional input, 24 bit

NEW

differential input, 2-/3-/4-/5-/6-

wire connection

distributed clocks

10 ksps oversampling

possible

free downsampling to 1 sps

ExtendedRange 107 %

measuring error in general

±0.01 % at 23 °C (±5 °C)

500 V electrical isolation

EtherCAT Terminals

EL3751 | Analog multi-functional input, 24 bit

NEW

Ok/Error LEDRun LED

+ Input 1 - Input 1

- Input 2

- UV

+ Input 2

+ UV

Vibration Monitoring with EL3632

PC-based control for wind turbines 05.11.2018 18

EtherCAT Terminals

EL3632 | 2-channel-analog-input terminal for CMS

acceleration sensors with ICP /

IEPE interfaces can be directly

connected

flexible and low-priced solution

TwinCAT Lib is required for analysis

or own analysis through the

customer

Max. sampling rate 40 kSamples/s

Resolution 16 bit

Run LED1

+Input 1

Power contacts +24 V

Power contact 0 V

Shield

Run LED2

+Input 2

-Input 2

GND

Shield

Error LED2

GND

-Input 1

Error LED1

Power Monitoring with EL3783

19

Power monitoring oversampling terminal for 690 V AC

Measuring range: Nominal * ExtendedRange

690 V (AC) * 130 %

5 A (AC) * 130 %

1 A (AC) * 650 % for detailed error case analysis

Current and voltage measurement of each 3 channels

with 20,000 samples per second

and measuring error <0.2 %

EL3783 │ Very fast and precise Power Monitoring

Measurement technology

The new EtherCAT-Measurement-Modules:

Very precise. Very fast. Very robust.

Fast: Up to 50.000 samples/sec with 24 bit

resolution

Precise in

time:

exact Synchronisation < 1 μs

by EtherCAT-Distributed-Clocks,

systemintern and external to reference clock

Precise in

value:

Accuracy of 100 ppm and better with high

temperature stability

Proactive: Integrated wire- and function diagnosis to

have a long-lasting high operation reliability

evaluation of measuring bridges

in full-bridge, half-bridge,

quarter-bridge configuration

internally switchable

supplementary resistors,

integrated feed

adjustment of supply voltage

and other values in the CoE

6-pin push-in plug removable

for maintenance purposes

ELM3504: 4-channel,

max. 100 μs/10 ksps

ELM3502: 2-channel,

max. 50 μs/20 kSps

ELM3504, ELM3502 | Measuring bridge analysis

Measuring of

IEPE sensors (vibration diagnostics, acoustics)

Voltage AC/DC single ended (0..20V, ±10V …±20mV)

0/2/4 mA constant current feed

and flexibly adjustable input

characteristics from DC to 10 Hz

internal scaler function:

transform [V] [m/s²] directly

Connectors:

0000: PushIn

0002: BNC connector

ELM3604-000x: 4-channel,

max. 50 μs/20 ksps

ELM3602-000x: 2-channel,

max. 20 μs/50 ksps

ELM3604, ELM3602 | IEPE analysis

over 30 different types of

electrical connections possible:

±30 V to ±20 mV, ±20 mA, full/

half/quarter bridge strain gauge,

IEPE, thermocouple, RTD, all

with a 2- to 6-wire connection,

depending on the type

ELM3704-0001: LEMO

connector, for changing sensor

configurations on a daily basis

(e.g. laboratory use)

ELM3704/ELM3702: 6-pin

with push-in, fast wiring and

less frequent unplugging for

maintenance (for industrial use)

ELM3704, ELM3702 | Multi-functional input

Where are EL3xxx, ELM3xxx in use?

Measurement applications

Automation

TwinCAT PLC

IPC

CX5020 Embedded PC

I/O

EtherCAT

EL3632 Condition

Monitoring terminals

Further EtherCAT

Terminals, e.g.:

EL5151 incremental

encoder interface,

EL3202-0010 PT100

input terminal and

EL3702, EL3742,

EL3356-0010 XFC

terminals

GfM Gesellschaft für Maschinendiagnose mbH,

Germany | Vibration diagnostics solution

IPC

Embedded PC CX5000

I/O

XFC Terminals

EtherCAT Condition

Monitoring terminal

EL3632

Automation

TwinCAT PLC

8.2 Monitoring GmbH, Germany

Condition Monitoring system

Automation

TwinCAT 3 PLC,

Scope View

Professional, Scope

Server, XML Server,

Database Server,

TC3 Interface for

MATLAB®/Simulink®

a. o.

IPC

Two 19-inch C5102

slide-in IPCs

CX5010 Embedded PC

I/O

EtherCAT

EtherCAT and

TwinSAFE terminals

Fraunhofer IWES Northwest, Germany

Test bench system for wind turbines

Measuring in the Beckhoff universe

Hardware

Metrological Automation | Scientific Automation

Standard

EL30xx, EL31xx

EP3xxx

Energy

Measurement

EL34xx, EL37xx

Time Synchronisation

(EL6688 IEEE 1588, PPS,

external clock, EL6695)

Safety

EL3xxx-

0090

ELx9xx

KLx9xx

Motion

EL7xxx

KL2xxx

Performance class Application examples

Fieldbus EtherCAT

154/183/45 = CMYK 35/0/0/15Runtime

154/183/45 = CMYK 35/0/0/15User Mode/Engineering

Software

Database

153/42/108Filter Library 153/42/108Power Moni-

toring Library153/42/108Condition Moni-

toring Library

PLC C++

HMI

HMI

153/42/108Time Sync.

Library153/42/1

08

NC/CNC

153/42/108MATLAB®/

Simulink®

153/42/108MATLAB®/

Simulink®

153/42/108MATLAB®/

Simulink®

153/42

/108

Database

Library

153/42

/108

Database

Server153/42/1

08

Connectivity

ADS

153/42/1

08

Connec-

tivity ADS,

OPC UA

Other Lab

View

153/42/108TC

Measurement

– Filter

Designer

153/42/108TC

Measurement

– Scope

View/Server

153/42/108TC

Measurement

– Bode Plot

153/42/108TC

Measurement

– Analytics

MES ERP TC Analytics

153/42/108SAP HANA®

Cloud Platform153/42/108Microsoft

Azure™153/42/108Amazon

AWS™

Precision

ELM3xxx

> 250 analog devices (IP20, IP67)

Condition

Monitoring

EL3xxx

Machine builder (location-independent)

Scenario: new business models with data analytics

Service technician (location-independent)

Machine Control

Customer 1

Machine Control

Customer n

Machine Control

Customer 2

Dashboard

MQTTMQTT

MQTTMQTTMQTT

Message BrokerTwinCAT Analytics

Storage Provider

Storage

IPC/VM

Interface to the WTC

Slipring

Blade Monitoring

Tower MonitoringDrive Train Monitoring

Blade Bearing Monitoring

Condition Monitoring | The Beckhoff Approach

1 Hardware, 1 Database, 1 Timebase, 1 Infrastructure

Electrical Power Monitoring

Drive Train Monitoring

Blade Monitoring

Blade MonitoringDrive Train Monitoring

Thanks!

05.11.2018 3333

Beckhoff Automation GmbH & Co. KG

Headquarters

Huelshorstweg 20

33415 Verl

Germany

Contact

Phone: +49 5246 963-0

Fax: +49 5246 963-198

E-Mail: info@beckhoff.com

Web: www.beckhoff.com

© Beckhoff Automation GmbH & Co. KG

All images are protected by copyright. The use and transfer to third parties is not permitted.

Beckhoff®, TwinCAT®, EtherCAT®, Safety over EtherCAT®, TwinSAFE®, XFC® and XTS® are registered

trademarks of and licensed by Beckhoff Automation GmbH. Other designations used in this presentation may

be trademarks whose use by third parties for their own purposes could violate the rights of the owners.

The information provided in this presentation contains merely general descriptions or characteristics of

performance which in case of actual application do not always apply as described or which may change as a

result of further development of the products. An obligation to provide the respective characteristics shall only

exist if expressively agreed in the terms of contract.